cover story knorr-bremse in the near and middle east · 2020. 6. 6. · near and middle east...

Edition 29 | April 2011

Cover storyKnorr-Bremse in theNear and Middle East

InnovationE3D and the "Intelligent" sliding step

ProductInnovative sand filtration system

QualityProcess model harmonized

R a i l V e h i c l e S y s t e m s

T h e c u s t o m e r m a g a z i n e o f K n o r r - B r e m s e R a i l V e h i c l e S y s t e m s

Publisher:Knorr-Bremse Systeme fürSchienenfahrzeuge GmbHApril 2011

Central Editorial Office:Knorr-Bremse Systeme fürSchienenfahrzeuge GmbHMarketingTanja MohmeMoosacher Strasse 8080809 MunichGermanyTel. +49-89-3547-0Fax.+49-89-3547-2767www.knorr-bremse.com

Conception, text and design by:Knorr-Bremse Systeme fürSchienenfahrzeuge GmbH

Text: Torsten Rienth

Design: KB Media GmbH

Layout, graphics: Cathrin Huber

Printed by: Weber-Offset GmbH

Information for the worldwide customers and business partners of Knorr-BremseE-NEWS-0029-ENThis publication may be subject to alteration without prior notice. A printed copy of this document may not be the latest revision. Please contact your local Knorr-Bremse representative or check our website www.knorr-bremse.com for the latest update. The figurative mark "K" and the trademarks KNORR and KNORR-BREMSE are registered in the name of Knorr-Bremse AG. Copyright 2011 © Knorr-Bremse AG. All rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.

Imprint:

Editorial Dr. Ralf Voß, 3 Member of the Executive Board, Knorr-Bremse Systeme für Schienenfahrzeuge GmbH

CSR Demonstrating responsibility 4

Innovation E3D and the "Intelligent" sliding step 7

News in brief Current affairs 8

Cover story Planning for tomorrow and beyond 10

Interview with Peter Karius 12

Desert metros 14

Product Innovative sand filtration system 16

Quality Process model harmonized 17

Project Brake and door systems 6 for Swiss Railways

Safety certificate for EP Compact platform 18

Moscow Metro: Opening and closing 19 every 48 seconds

Location Expansion in Suzhou 20

Exhibition UITP 2011 in Dubai: Global solutions 22

CONTENTS


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2010 was a successful year for Knorr-Bremse, with further growth in the Rail Vehicle Systems division driven by a significant sales increase in Asia. This was not just triggered by the current economic upturn – it was also the fruit of our long-term corporate strategy of maintaining a local presence on a global basis. We offer customers throughout the world a combination of systems competence, innovative products and comprehensive aftermarket service .

We have deliberately chosen the Middle East as our focus, as many of the countries in the region have experienced unprecedented growth in rail transportation over the last ten years – whether in the form of high-speed trains in Turkey or metros on the Arabian Peninsula. While investment in public transport systems is currently subject to critical review in many parts of the world, in the Middle East planning is well underway and in many cases construction has already started. Another reason for the focus of this Informer is that Dubai is hosting the 59th World Congress of the International Association of Public Transport (UITP) from April 10 to 14, and Knorr-Bremse will be represented at this event with an exhibition stand.

Many innovative Knorr-Bremse products are already well established in the region –for example the Westinghouse platform screen doors installed in Mecca Metro, which ensure platform safety on a metro system capable of transporting 72,000 passengers per hour in each direction. You can read more about this project on pages 14 and 15, and on page 16 you will find a description of the new HVAC system with sand filter that was specially developed by Knorr-Bremse‘s Spanish subsidiary, Merak for the climatic conditions in Saudi Arabia.

This edition of the Informer includes further interesting articles: we report on Knorr-Bremse's membership of the UN Global Compact and the responsibilities this brings; we describe the expansion of the Knorr-Bremse site in Suzhou, China; and we introduce the new E3D door system and intelligent sliding step from IFE. Other articles focus on safety certification of a modular electro-pneumatic braking system, important successes in North America, the TWINDEXX Swiss Express project and Moscow Metro, for which Knorr-Bremse is supplying several different systems. Further innovations will be presented at the UITP in Dubai.

We would be delighted if you could join us there at Stand C200 in Hall 8.

We look forward to seeing you!

Kind regards

Dr. Ralf Voß

Dr.RalfVoß,MemberoftheExecutiveBoard,Knorr-BremseSystemefürSchienenfahrzeugeGmbH

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Corporate Social Responsibility

Demonstrating responsibility

Five years after Knorr-Bremse Global Care was first set up with the aim of helping people in need to help themselves, the decision to join the UN Global Compact marks a further important milestone in the company's realization of itscorporate responsibilities. The Global Compact was set up in 2000 by Kofi Annan, then UN Secretary-General, andparticipating companies commit to actively contributing towards making globalization a more equitable process in social, environmental and economic terms.

By signing up to the Global Compact, Knorr-Bremse has undertaken to support the ten principles in the fields of

environment, labor, human rights and anti-corruption and to mainstream these in its corporate activities. More than 6,000 companies all over the world are members of the UN Global Compact, and the German Global Compact Network includes more than 140 companies as well as public and civil society organizations such as the Federal Ministry for Labor and Social Affairs and Amnesty International.

The timing of Knorr-Bremse's membership of the Global Compact was carefully chosen. Following the drawing up of the company's CSR strategy (see box), social responsibility is now an integral element in its overall corporate strategy. "We want to use our CSR strategy to strengthen businessdevelopment and corporate culture and ensure that ouractivities contribute towards sustainable development of the economy and society," explains Julia Thiele-Schürhoff, Head of the Central Corporate Social Responsibility (CSR) Department. Building on the strategy, an ambitious CSR program is to involve a number of further specific activities. Following the successful introduction of the first stage of the ECCO2 climate strategy for improving energy efficiency, other measures are to include a pilot project for carrying out CO2 audits at Knorr-Bremse sites, a review and analysis of suppliers' environmental and social standards, and integration of CSR aspects into Knorr Excellence processes.

JuliaThiele-Schürhoff,HeadoftheCentralCorporateSocialResponsibility(CSR)Department


Knorr-Bremse has signed up to the UN Global Compact, committing itself

to supporting ten globally recognized basic principles in the fields of

environment, labor standards, human rights and anti-corruption. The new

Knorr-Bremse Group CSR strategy places corporate responsibility and

sustainability at the very heart of corporate strategy.

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Compact as an important, globally recognized benchmark. Together with the company's corporate values and the UITP (International Association of Public Transport) Charter for Sustainable Development, the ten principles enshrined in the Global Compact provide a basis for all Knorr-Bremse's activities in the field.

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For some time now, several major customers have expected Knorr-Bremse to provide information about its compliance with and management of environmental and social standards or to sign up to an appropriate supplier's code. In so doing they make explicit reference to the ten principles of the Global Compact. Knorr-Bremse, too, is currently developing a standard code of behavior for its own suppliers and is using the Global

TheprinciplesandfieldsofactionfortheCSRstrategy

CSR StRategy: a StRategiC appRoaCh to CoRpoRate ReSponSibility The company's newly formulated CSR strategy systematically details how the company perceives its responsibilities in relation to the environment, the workforce and society as a whole, and what its main areas of focus are going to be in the future. Starting with Knorr-Bremse's commitment to assume day-to-day responsibility for ensuring that people and goods reach their destination safely, the statement "Responsibility brings safety" sums up the aim of the CSR strategy: Knorr-Bremse is determined to live up to the trust that is placed in the company on a daily basis and to operate as a responsible and reliable partner in times of social change.

The CSR strategy contains five guidelines that lay down the company's main objectives. Activities are aimed at developing the business and strengthening corporate culture, protecting against risks, using global and local activities to contribute towards sustainable development and creating a positive public image for Knorr-Bremse. Sustainability is of particular importance for Knorr-Bremse as a family business, and this implies not only long-term business planning but also measures to secure a future based on economic, environmental and social balance – which should benefit customers as well.

KnoRR-bReMSe intenDS to FoCUS itS aCtiVitieS on SiX aReaS:

Strategy and management Products and partners Environment and climate Employees and management Commitment and society Communication and cooperation

Every year, the CSR program will lay down specific objectives and measures for these areas. With its activities in the field of "products and partners" Knorr-Bremse helps customers save energy and conserve resources and works with its busi-ness partners to implement higher environmental and social standards. For 2011, for example, the program includes a process of dialogue and benchmarking with key customers, greater promotion of energy-efficient products and a pilot project for auditing CO2 emissions at the company's plants.

project tWinDeXX Swiss express

Brake and door systems for Swiss Railways

Knorr-Bremse is to supply braking and door systems for 59 TWINDEXX trains

ordered by Swiss Railways. In addition to vehicle body components – including

the EP compact brake control system – the package includes complete

bogie equipment, air supply modules with oil-free compressors and new

E3D door systems.

The order covers nine 4-section and fifty 8-section trains, with delivery of the first components scheduled for the end of 2011, and the completed vehicles due for deliverybetween 2013 and 2019. The first trains will go into service from December 2013 onwards. An option for more than 100 further trains has been agreed between Bombardier and Swiss Railways and Knorr-Bremse is in the running to supply the braking systems for these too.

If all the options are included, this constitutes the biggest single order ever received by Knorr-Bremse's subsidiary IFE. The fact that the company won the order for 1,664 passenger doorsets, 40 loading doors and 40 catering doors was due to a number of factors, one of which was the impressive display

it had given of a fully functioningprototype of the new door design at last year's InnoTrans trade fair. It also put huge effort into preparing the tender, producing all the technical documentation and several of the commercial documents to a degree of detail that is rare at that stage of the process.

Swiss Railways insisted on the doors being designed to be as wide as possible in order to ensure a smooth flow of passengers. And with passenger comfort in mind they

also required the door seals to withstand the over-pressure caused by traveling at high speeds and through tunnels. The development engineers came up with a special design of extra-wide, single-leaf, pressure-reinforced door.

The TWINDEXX double-decker multiple units operated by Swiss Express are some of the most modern rail vehiclescurrently available. They include a large on-board restaurant and a spacious family car, as well as a business compartment offering space for business people to hold meetings or work undisturbed. All seats are equipped with electrical sockets and Wi-Fi Internet connection.


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Source: Bombardier Source: Bombardier

Presented for the first time at the 2010 InnoTrans trade fair in Berlin, the

new E3D train access system from IFE is designed to offer higher standards

of safety, reliability and comfort.

Passengers enjoy high levels of comfort thanks to a generous opening width and an efficient pressure seal when closed.

E3D is an electrically operated single-leaf pressure-reinforced door system designed for high-speed trainstraveling at up to 300 km/h. It is essentially a combination of the well-known E3 and DET systems with additionalfeatures such as a compact installation envelope, a highdegree of pre-assembly and easy maintenance.

The E3D prototype showcased at InnoTrans 2010 featured a clear opening width of 1,400 mm and excellent pressure resistance, as well as high levels of reliability, with a passive sealing system that avoids the problem of inflatable seals.

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new technologies from iFe

E3D and the "Intelligent" sliding step

For a door to withstand high pressures, the seal has to run without interruption around the entire door leaf – which is why access systems for high-speed trains exclusively use single-leaf doors.

E3D also has a highly sensitive obstacle detection system with two electrical safety switch strips in the main doorframe.

The doors and steps have been designed for the Swiss Railways TWINDEXX project.

intelligent SliDing Step

In addition to the new door system showcased at InnoTrans 2010, IFE also presented a sliding step developed fordouble-decker trains.

Using a special mechanism the step adapts to the gap between train floor and platform. It is equipped with an ultrasound sensor that measures the distance from the platform and calculates how far it needs to extend, stopping the stepautomatically between 3 and 4 centimeters from the platform edge. This precise adaptation to the gap and height difference between step and platform offers greater safety for children and elderly people.

The sliding step is also equipped with a contact strip that prevents passengers from becoming caught in the step. The system is currently undergoing testing by Swiss Railways.

ThemechanicalpropertiesoftheE3DsystemcombinedwiththeDETsealingsystemenablethedoortowithstandexternalpressuresof6,000pascals.Thesimple,robustclosingmechanismcontributestothedoor'sreliability.

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News in brief andcurrent affairs

Series assembly of door systems

Door manufacturer IFE has further expanded its door assembly services. In addition to first assembly, it now also offers specific assembly aids and diagnostic instruments – or it can even carry out full seriesassembly for the customer. In 2009 the company signed a framework agreement with AnsaldoBreda covering assembly and assemblysupport for all the door systems it supplies. And in 2010, as part of the negotiations on equipping the FLEXITY 2 platform, IFE also concluded an initial agreement on door system assembly with Bombardier.

Vehicle manufacturers are increasingly relying on specialized systems suppliers to take over the task of door assembly. Using expert technicians from the original equipment manufacturer is the only way to ensure correct installation. When IFE assembles the door systems itself the company is able to offer a guarantee that includes pre-defined standards of reliability. Such high standards can only be achieved through skilled assembly by an expert.

Major service contract for Merak

Early this year, Knorr-Bremse subsidiary Merak North America signed its biggest ever service/repair HVAC contract with Metro North Rail Road.

The contract covers the overhaul of 850 HVAC units for the suburban operator's M7 series vehicles. Delivery of the units began in June 2009 and is scheduled to end in March 2014. For the five-year service/repair contract the scope of work includes incoming and outgoingfunctional tests, individual component inspection, cleaning,replacement of identified components, and refrigerant replacement. Once Merak has finished the last of the five year service/repair tasks on the 850 HVAC units, the first units delivered in 2009 will be due for their ten year overhaul program.

Thanks to Merak North America's performance and levels of customer satisfaction on this Metro North Rail Road service/repair contract, the company has received several inquiries from other transit authorities about carrying out their service/overhaul programs.

End-of-year figures for 2010

In fiscal 2010 the Knorr-Bremse Group increased sales revenues byalmost EUR 1 billion, or 34%, to EUR 3.7 billion. The increase includes positive currency translation effects in the amount of approximately EUR 170 million. Assuming constant exchange rates, year-on-year operational growth stood at 28%. Sales at the Rail Vehicle Systems division moved ahead from EUR 1.5 billion in the previous year to EUR 2.0 billion in 2010. The increase was primarily driven by a marked rise in sales of over 100% in Asia, where Knorr-Bremse has been progressively expanding its market presence since the late 1980s.


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Significant contract from Washington D.C.

In 1998, Knorr-Bremse was awarded a contract to supply 110 car sets of braking system equipment for the Washington Metropolitan Area Transit Authority (WMATA) 5K series. In December 2010, the company received another major order from WMATA.

Just two years after the 1998 order, WMATA placed an option order for an additional 82 car sets of braking equipment. And in 2002 and 2004, equipment for further cars was ordered from Knorr-Bremse's subsidiary Knorr Brake Corporation. The orders also included HVAC systems from Merak and door systems from IFE. In March 2010, WMATA awarded Knorr Brake Corporation a contract for replacing 182 of the existing compressors with VV120-T oil-free air supply units.

The most recent success for Knorr-Bremse was in December 2010, when Knorr Brake Corporation and Merak North America were awarded a contract to supply the WMATA 7K series with 364 car sets of braking systems and HVAC equipment. Option orders exist for an additional 384 car sets. Delivery of pilot cars is scheduled in 2012, with series production starting in 2013 and ending in 2017.

The braking system is consistent with Knorr-Bremse's normal scope of supply, which includes the VV120-T oil-free air supply unit, emergency pipe control unit, truck control unit, ESRA electronic control unit, and

Patience and perseverance pays off

A new chapter has begun in the successful partnership between Knorr-Bremse and the Northeast Illinois Regional Commuter Railroad Corporation (METRA) with an order for 160 car sets of brakingequipment.

It was back on July 11, 2003 that Knorr-Bremse, through its subsidiary Knorr Brake Corporation, was awarded a contract to supply 26 car sets of brake equipment for the Northeast Illinois Regional Commuter Railroad Corporation Electric Multiple Units program.

On December 23, 2010 Knorr Brake Corporation received an order for a further 160 car sets of brake equipment for METRA's new Electric Multiple Units procurement program. As with the original order, the scope of supply includes a VV120T oil-free air supply unit, emergency pipe control unit, truck control unit, ESRA electrical current unit, PEC7 Tread Brake Units (Block Brakes) and Master Controller. Delivery of the prototype cars is scheduled for August 2011, with series production starting in November 2011 and ending in May 2015.

WZK calipers. The Merak HVAC system will consist of two stainless steel unitized roof-mounted assemblies.

The award of the 7K series brake and HVAC systems contract was adirect result of Knorr-Bremse proven systems reliability, availability and company's approach to customer service.

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Source: Wikipedia © amtrak_russ


planning FoR toMoRRoWanD beyonD

Knorr-bremse in thenear and Middle east

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planning FoR toMoRRoWanD beyonD

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over the past ten years the near and Middle east has been a global pacemaker in the development of railtransportation systems. Fromistanbul to Mecca, new streetcar and metro systems, freight and high-speed lines are being planned and built in an effort to meet growing demand for transportation of passengers and goods. the focus is also on developing an attractive infrastructure for the post-oil era.

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ThecountriesoftheNearandMiddleEastarenolongerjustfamousfortheirskyscrapersandartificialislands.Whyisitthattheseregionsareinvestingsomuchinrailtransportation?Peter Karius: There are various factors involved. In Istanbul, it is driven by rapid population growth. In cities like Abu Dhabi, it is the result of careful urban planning. In Mecca, the focus is more on pilgrim tourism. Of course the Soccer World Cup in Qatar will also bring a tremendous boost to the rail sector. Sometimes it's also a question of prestige – but that's the same the world over.

Whyhasthestatusofrailtransportationriseninrecentyears?Peter Karius: It can largely be explained in historical terms. Certain railroad lines – for example between Istanbul and Baghdad – already exist, but it is no secret that they have been getting rather long in the tooth. Between 1970 and 2000 relatively little happened in terms of buying new vehiclesreconditioning, repairing or replacing existing ones and extending lines. Now people are catching up – and thatincludes metros, trams and freightnetworks as well as high-speed lines.

Theseareallverydifferentcountries–buttheyallagreeabouttheneedforrailroads?Peter Karius: Yes – that's true. But their approaches differ. Smaller states like Qatar, Kuwait or cities like Dubai are planning to use a wide range of dif-ferent transportation systems. SaudiArabia is working on a north-south freight connection to transport phosphate, which is mined in the north of the country. The locomotives have already beenordered – and Knorr-Bremse is supplying the brake control systems. And then there is Mecca. The Saudi Arabians have to find ways of coping with theextraordinary challenges of pilgrim tourism. So they're not only completing Mecca Metro but also giving priority to the creation of a high-speed line linking Mecca, Jeddah and Medina.

That'salotofbuildinginonego.Peter Karius: There are also two further major visions for the region. The first is a long-distance network connecting all the countries of the Gulf. A linkbetween the individual states of the United Arab Emirates is already being planned and the first calls for tender have gone out. The idea is to extend the line from Kuwait along the Arabian Peninsula to Yemen at a later stage. But these are long-term plans. The other vision involves a line connecting Saudi Arabia directly with Europe.

ItseemsasthoughallthegrowthisconcentratedontheArabianPeninsula.WhataboutTurkey?Isitplanninganythingsimilar?Peter Karius: Turkey tends to be very much underestimated with regards to rail. It has a population of 70 million – more than all the countries of the Ara-bian Peninsula put together! Not only the major conurbations but also towns with less than a million inhabitants have started to develop their own streetcar networks. And then there is the high-speed network that will link a number of major cities in the east of the country with Ankara, the capital, and Istanbul. Some of that line is already in operation. It's a huge project. In recent years in Istanbul alone, vehicles have beenordered for four metro lines – more than in Dubai.

Whenitcomestoplanning,towhatextentdoesthedeclineoffossilfuelsplayarole?Peter Karius: It plays a very prominent role. Of course many of these countries are trying to open up new sources ofincome. The building of a railroad line to the phosphate deposits I mentioned in the north of Saudi Arabia is an example. And Dubai is hoping to exploit itsposition as a trade and exhibition center and an aviation hub – which, of course, requires a modern local public transport system.

The Informer editors spoke to Peter Karius, Executive Manager International

Sales at Knorr-Bremse Systeme für Schienenfahrzeuge GmbH.

"people in the Middle east think in generations rather than years."


Knorr-Bremse offers solutions for all system types.

PeterKariusgraduatedwithadegreeinindustrialengineeringfromMunichUniversityofAppliedSciencesin1991.SincethenhehasheldvariouspositionsinSalesandSystemsatKnorr-Bremse.HehasbeenExecutiveManagerInternationalSaleswithresponsibility,amongstotherthings,forthecountriesoftheNearandMiddleEastsinceearly2007.

Whatstrikesoneaboutmostoftheseplansisthattheyareverymuchlong-term.Peter Karius: Yes – the United Arab Emirates in particular arethinking in the long-term. They have developed visions for their cities and are planning the infrastructure to go with them from the outset. In many ways that is a better approach than expanding transportation systems on a piecemeal basis after the event. Abu Dhabi, for example, has a "Masterplan 2030" that involves massive expansion of the city and its rail systems. In both the Near and Mid-dle East people think in generations rather than years.

Wherethereareopportunitiestherearealsorisks.Whataretherisksinthiscase?Peter Karius: Growth in this region cannot be taken for granted, that much is clear. We've already seen, during the economic crisis, how projects can disappear from the list. But generally speaking I think the outlook for the region is very good. On the other hand, political stability plays an important role. And, as always, it is difficult to look thirty years into the future. We've seen in Egypt, Tunisia and elsewhere how unexpected change can suddenly take place. But one trend can be predicted: more and more orders are going to come in from Asia – which is by no means bad news for us. We have a very strong foothold in the key markets in China, Japan and South Korea and various different technical standards are no obstacle – Knorr-Bremse offers solutions for all system types.

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"people in the Middle east think in generations rather than years."

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September 9, 2009 was a special date, even for a city like Dubai that is used to superlatives. It was then that the first metro system in the Middle East –at 75 km the longest fully-automated railroad system in the world – was officially opened. On the day of the opening ceremony the eyes of the entire world were focused on this prestigious technological project on the Arabian Peninsula.

The 2,000,000-odd inhabitants of the city have been quick to take advantage of the new metro line – trains are well filled and the positive impact on the city's often congested streets can clearly be felt. Before the end of the year a second line is due to open, with the trains also being equipped by Knorr-Bremse.

Another factor in the metro's success was the platform doors supplied by Westinghouse Platform Screen Doors (WPSD), which enable passengers to embark and disembark rapidly,

they are safely and comfortably during the rush hour. Other cities are also coming to realize the advantages of a properly equipped metro system – Abu Dhabi is currently prioritizing the planning of its own metro system.

SaFety in the DeSeRt SanDS The story is similar in Mecca, where the first of five planned metro lines opened in time for last year's Hajj – the pilgrimage that brings some three million Muslims to the holy city every year. The crowds are so great that there is often a dangerous crush in the city's various thoroughfares. Mecca's investment in a metro system proved invaluable during the first Hajj as it considerably reduced the hours pilgrims had to spend travelingbetween the various religious sites.

As in Dubai, the operators of Mecca Metro have relied on the technical competence of Knorr-Bremse. The

company was responsible fordeveloping the entire brakingequipment for the vehicles, with crucial components being specially designed to operate in the extreme local climate. To prepare their products for desert conditions, Knorr-Bremse and itsSpanish subsidiary Frenos evensimulated sandstorms to test the EP2002 brake control system andoil-free compressor. The response from the operators in Mecca has been extremely positive.

biggeSt Single oRDeR in the CoM-pany'S hiStoRy All the stations in Mecca are also equipped with door systems from Knorr-Bremse subsidiary Westing-house Platform Screen Doors. The first deliveries were made in time for the Hajj in November 2010 and represented a record for the company: never before had so many platform screen doors been installed in such a short time.

Dubai was the first city in the Arabian Peninsula to start building a metro

system, followed shortly afterwards by Mecca. Trains in both cities are

equipped with state-of-the-art products from the Knorr-Bremse Group.


brake and door systems in the orient

DesertMetros

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Within 18 months of receiving the order, 1,140 doors were ready for operation at Arafat, Muzdalifah, Mina and Jamaraat stations. In a mere four months the company had installed door systems equivalent to a platform length of 5.6 km.

With completion of the first section, about 50% of the finalcapacity of Mecca Metro is now available. Once the second section opens, the system will be capable of transporting some 72,000 passengers per hour in each direction. Work on this section began immediately after the last Hajj, and by the time it is completed, Westinghouse Platform Screen Doors will have installed a total of 1,865 doors in Mecca.

Picturedonoppositepage,bottomleft:WestinghouseplatformedgedoorsinMakkahenhancesafetylevels

Picturedonoppositepage,bottomright:OneofthefuturisticelevatedstationsonDubaiMetro

Picturedtopleft:TheplatformarchitecturetreatmentsofMakkahMetropayshomagetoSauditraditions

Picturedbottomleft:DubaiMetroplatformsarecolorandtreatmentthemed;air,earth,fire,orwater.Thisisanexampleofan"air"themedplatform

Picturedbottomright:PartofanelevatedstretchofDubaiMetropicturedagainstsomeofthecity'sincredibleskyscrapers


Knorr-Bremse subsidiary Merak designs and manufactures HVAC systems for all extreme

climatic conditions, including desert terrain where temperatures can reach above 55ºC. In

these extremely dry conditions, airborne sand and other particles are a serious issue and

it was necessary to adapt HVAC systems in order to ensure air quality and high efficiency.

Air quality has always been a priority for Merak. UV-C lamps and CO2 level detectors have already been installed in several HVAC systems with more than successful results. Thesesolutions underline Merak's concern and interest in thisissue.

Now, as part of its air-quality improvement initiatives, Mer-ak has developed a sand filtration system for incorporation into HVAC systems that separates sand and other particles from fresh air. This innovative system represents a further advance in high-end HVAC technology.

the SanD FiltRation SySteM iS baSeD on the FolloWing StageS:

Fresh-air grilles: Prevent large particles or water from entering the system. Depending on the wind direction and direction of travel, air is taken in from one side or the other of the train. In the case of a sandstorm, grilles from both sides can even be closed, protecting the system.

Cyclonic filters: Air is directed through cyclonic filters to separate sand and only let clean air pass into the unit. A turbo ventilator then removes the sand from thecyclonic separator. This "auto sand emptying" is a way of reducing maintenance costs.

Filter bags: The air then passes through specifically sized filter bags, where the remaining particles are

totally removed.

The result is that only clean air, free of sand, runs through the HVAC unit, hugely improving air quality inside the train.

This innovative sand filtration system is a result of continuous research and development work by Merak. Despite its success, Merak will continue investing efforts in order to remain a pioneer in the field, offering the best adapted solutions for its customers' needs.

We would be delighted if you could find time to visit us at our booth at the UITP exhibition in Dubai, where this new equipment, including the sand filtration system, UV-C lamp, and CO2 level detector, will be presented in detail.

heating, ventilation and air conditioning

Innovative sand filtration system

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At the turn of the year the Rail Vehicle Systems division took over the

Knorr-Bremse AG process model, thereby establishing a uniform worldwide

standard for the entire Group.

For several years, Knorr-Bremse has combined initiatives aimed atcontinuous improvement of business processes under the Knorr-Excellence program. This program brings together all process-optimization initiatives on a cross-divisional basis and also creating a standard process model for its management systems based on the Malcolm Baldrige, Deming or EFQM quality awards.

ContinUoUSiMpRoVeMentThis has created a common platform within the Group that also benefits Knorr-Bremse Rail Vehicle Systems in the long term. It facilitates access to business processes and improves communication within the company, as well as promoting a betterunderstanding of process management and implementation. Such coordination also makes internal benchmarking

structures to be combined with new, innovative approaches.

The process stability this offersapplies to all parts of the company, from product planning logistics via production right down to delivery of a wide range of different components. Ultimately customers, too, stand to benefit from these changes, as they can be certain that Knorr-Bremseproducts continue to be manufactured to the highest standards.

Rail excellence

Process modelharmonized

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possible – which again ensures ongoing improvement of processes.

In order to retain tried-and-tested processes the existing structures and process organization within thecompany were retained, with the 23 processes making up the Rail Excel-lence management system beingallocated to the nine elements of the new process model. They have been renamed, but the documentation structure and content of all processes remain unchanged – enabling proven

For the first time ever a modular brake control system comprising electronic and pneumatic components wasinspected according to CENELEC safety standards EN 50126, EN 50128 and EN 50129.

The certificate, which is valid world-wide, confirms that basic braking functions have met the respective safety targets:

System safety function Emergency Braking SIL 4

System safety function Wheel Slide Protection SIL 3

System safety function Service Braking SIL 2

System safety function Parking Brake SIL 2

The safety function "EmergencyBraking" was assessed according to the highest possible safety integrity level SIL4. An EN ISO/IEC 17020accredited institution (TÜV Süd)certified the brake system architecture, the hardware and softwarecharacteristics and the associated pneumatic unit for the safety functions listed. In addition to this “functional safety” the certificate also confirms conformity of processes and working methods to the V-model systemsengineering process established at Knorr-Bremse.

The independent safety management at Knorr-Bremse organized within the "Product Safety Group" accompanied

the development, compiled the safety case and steered the certification process.

Generic, project-independent certification of EP Compact saves vehicle builders time and money. A product certificate speeds up the vehicle approval process and demonstrates to the authorities that the vehicle is equipped with a safe, state-of-the-art braking system.


Safety Management

Safety certificate forEP Compact platform

Following a comprehensive, cross-disciplinary safety case procedure,

Knorr-Bremse has successfully achieved certification of the EP Compact

brake control system.

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Moscow Metro

Opening and closing every 48 seconds

The first order for the Type 81-760/761 covers 53 vehicles that are due for delivery during the course of 2011. Almost 800 door sets have already been built at IFE's productionfacility in the Czech Republic since last November. Parallel to the order for doors, Knorr-Bremse is also supplying Metro-vagonmash with the oil-free compressors, block brake units and brake resistors.

The orders received from Metrovagonmash have further strengthened the position of Knorr-Bremse in the Russian metro market: Type 81-760/761 and Type 81-740 trains are all equipped throughout with Knorr-Bremse VV120-Tcompressors and Microelettrica brake resistors.

Purchasing new trains is part of the City of Moscow's ongoing upgrade of its

metro system. The latest generation of Metrovagonmash Type 81-760/761

vehicles currently going into service has several Knorr-Bremse systems on

board.

With more than nine million passengers every day, Moscow Metro is one of the busiest networks in the world. The new trains from Metrovagonmash are equipped not only with Knorr-Bremse's VV120-T oil-free compressors, PC7 block brake units and brake resistors from Microelettrica, but also with door systems from Knorr-Bremse's subsidiary IFE. The Russian train manufacturer, in partnership with Moscow Metro, opted for IFE doors to ensure that the new trains were provided with state-of-the-art technology. Moscow Metro operates its trains at extremely short intervals of as little as 48 seconds, so it is crucial for the doors to function reliably and efficiently.

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Growing demand means Knorr-Bremse plant in Suzhou, Jiangsu province, is

once again expanding – just a few years after it was first enlarged. Now the

focus is not only on production but also on aftermarket capacity.

Expansion of Suzhou II plant

Expansion in Suzhou


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being introduced in close collaboration with the company's other service centers and production units world-wide.

ConSiStent qUality StanDaRDS The state-of-the-art equipment used for service operations in China can stand comparison with Europe – and the same goes for the tools, key performance indicators and tried-and-tested methods of the Knorr-Bremse Production System KPS. This means Knorr-Bremse can be sure of maintaining consistent quality standards all over the globe.

Growth in the Chinese rail market began to accelerate some ten years ago, and expansion continues apace. Many of high-speed routes have been planned and completed. With the backing of the Chinese government, a number of China's megacities have invested in new metro systems or expanded existing ones. At the same time, the state-owned railway company has started to invest in modern locomotives, metros and high-speed trains manufactured in Europe. By the end of 2010, for example, 3,500 locomotives and over 4.000 metros equipped with Knorr-Bremse systems were in operation, and a further 1,000 locomotives and 1.200 metros are due for delivery in 2011.

CoMpRehenSiVe eXpanSionFaced with such market growth, there was inevitably a need to expand operations in Suzhou, where Knorr-Bremse'smanufacturing, sales, project management, design,procurement and accessory production are concentrated. Work therefore started in the summer of 2010 on expanding Suzhou II, the modern facility constructed by Knorr-Bremse as recently as 2007 in response to growing demand.

The first step involved the building of new staff facilities: a new canteen, changing rooms and shower facilities and expanding infrastructure. Then an additional production area measuring 6,500 m2 and a staff area of some 2,500 m2 were added. By the time the project is completed, the Suzhou plant will cover a total area of 22,500 m2 and employ a workforce of up to 1,000. In addition to the physicalexpansion, manufacturing processes have also beenupgraded.

The new facilities at Suzhou II will provide more space for accessory production, assembly operations, recycling and storage of waste and dangerous substances. Knorr-Bremse has also used the opportunity to raise its environmental standards by adding extra heat insulation and installing a rainwater tank and solar module.

loCal aFteRMaRKet SeRViCe In addition to responding rapidly to increased demand for braking system components, Knorr-Bremse has also created additional aftermarket service capacity at Suzhou. As was to be expected, the large volume of systems supplied over the last ten years has begun to trigger demand for aftermarket services. Knorr-Bremse has invested in two areas, establishing a service center in Suzhou and at the same time expanding its field service teams. In both cases the company hasendeavored not just to extend its service capacity but also to enhance its employees' maintenance skills. The changes are

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Innovative capability, all-round service and outstanding systems competence:

at the 59th World Congress of the International Association of Public Transport

(UITP) to be held in Dubai from April 10 to 14, 2011, Knorr-Bremse will be

showcasing its response to current and future market requirements.

Uitp 2011 in Dubai

Global solutions

In an increasingly mobile world an ever expanding role is being played by rail vehicles of all kinds. The UITP congress and exhibition scheduled to take place in Dubai in April will bear the motto "Boosting public transport: Action!"Companies from all over the world will be presenting their latest public transport solutions.

Knorr-Bremse Systeme für Schienenfahrzeuge GmbH and its subsidiaries will be among the exhibitors, showcasing groundbreaking products that make rail transportationsafer, more efficient and more eco-friendly.

Displayed will be a platform edge door system from


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Westinghouse Platform Screen Doors (WPSD) of the type installed on Makkah Metro. This system demonstrates how the operation of modern stations can be both safer and cleaner. Train doors are an important safety factor, and IFE will be showcasing its new S3 door system, which offers equal degrees of safety, economy and reliability. The same goes for the new HVAC systems that will be presented by Merak. Microelettrica will be showing exhibits from the field of power supply electronics and Knorr-Bremse itself will be presenting the weight-saving EP Compact lite as well as the well-known EP2002.

Also on show will be a hydraulically operated brake caliper with hydraulic unit, the WZK compact pneumatic brake caliper for all types of vehicle with disc brakes, and the VV120-T oil-free compressor. With its specially coated piston and

cylinder and Teflon piston rings, the compressor does away completely with the need for oil lubrication, offering much greater economy and efficiency combined with lowerenvironmental impact than conventional piston compressors.

It is no coincidence that this year's UITP Congress is taking place in Dubai. In recent years the city has developed an unrivalled public transport system in a bid to cope with rapid population growth. By the year 2020 the city is set to have 318 kilometers of metro line and a 270-kilometer streetcar network.

R a i l V e h i C l e S y S t e M S

through-out the world, Knorr-bremse products are used to move people and goods safely. in all types of railvehicles, carrying passengers and freight – and on platforms. that is why quality is so important for us. ourQuality First Initiative helps us create products that will function reliably throughout a long working life. our goal of Zero Defect starts with the initial development stage and culminates in carefully designed manufacturingprocesses with regular quality control procedures. that way, everyone stays on the right track – our customers and our customers' customers. | www.knorr-bremse.com |

quality thatconvinces.

Visit us atUITP Dubai,

Hall 8Stand C200

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